Deutz EMR2 Electronic Engine Governor

System Description Electronic Engine Governor

EMR 2

EMR 2 Chapter Overview

Chapter

Introduction

1

Important Notes

2

System Description

3

System Functions

4

Interfaces

5

EMR 2 Chapter Overview

1

2

3

4

5

EMR 2 Table of Contents

Contents

Page

1

Introduction

65

2 2.1 2.2 2.3 2.4 2.5 2.6

Important Notes Operating instructions Installation guidelines Damage Customer side wiring, plug connection Remove plug Electrical welding

67 67 67 67 68 68 68

3 3.1 3.2 3.3 3.4

System Description Utilization of the EMR 2 System overview Description of functions Basic equipment

69 69 69 70 70

4 4.1 4.2 4.3 4.4 4.5

System Functions Overview features Function extensions Speed control Set point settings Fuel quantity limitation (performance curve)

71 72 73 74 76 77

EMR 2 Table of Contents

9 9.1 9.2 9.3 9.4

Technical Data General Data Signal Specification Plug assignments Sensor Data

101 101 102 103 105

10

Index of Specialist Terms

107

11

Index

109

12

Connection diagrams

113

12.1 12.2 12.3 12.4

Appendix Connection diagram - Vehicle side / Unit side Connection diagram Engine side (sheet 1) Connection diagram Engine side (sheet 2) Connection diagram for CAN-Bus and Diagnostic Line

115 115 116 117 118

EMR 2 Introduction

1

Introduction

This system description provides an overview of the design and o peration of the electronic engine governor (EMR 2) as a control unit when used in engines of the model series 1012/1013/2012/2013/1015 1). In addition, an explanation is given of the functions of the EMR 2 and how problems with the EMR 2 can be recognized and overcome. The EMR 2 is a further development of the previously utilized EMR. Basically, it has the same functionality as the EMR, but is equipped with additional functions and extensions that are summarized in Chapter 4.2. Reference is made to Chapter 8 for information regarding replacements,

1

2

1) Same system with Bosch EDC-actuator (1015).

3

General notes

4

It is our aim to permanently improve and extend the contents of this brochure. For this purpose, the experiences of the circle of users can be particularly helpful. Should you desire changes, extensions, improvements, etc., we would welcome your input (Engine maintenance technology department, VS-TI). Please make as much use of this as you wish. In this way, you are

5

EMR 2 Introduction

1

2

3

4

5

EMR 2 Important Notes

2

Important Notes

2.1

Operating instructions  IMPORTANT!

The purpose of this document is the explanation and clarification of the design and functions of engines, engine components and systems. The information contained herein always corresponds to the technical conditions valid at the time of going into print and are not subject to any immediate alteration service.

1

2

 IMPORTANT!

Applicable for the operation, maintenance and start-up are exclusively the information of the published and currently valid technical documentation, corresponding to the scope of delivery and function (such as operating instructions, switching diagrams, workshop manual, repair and adjustment instructions, technical circulars, service information, etc.).

3

4 2.2

Installation guidelines  IMPORTANT!

For the mechanical installation of the apparatus, reference should be made to the applicable issue of the “Installation Guidelines for electronic systems of DEUTZ diesel engines”. More

5

EMR 2 Important Notes

2.4

Customer side wiring, plug connection  IMPORTANT!

In order to attain the required protection class (IP 66) at the control unit, the individual wire seals, plugs and sealing rings provided must be used.

1

 IMPORTANT!

The connection between pins and individual wires must only be carried out with the proper pinching tools.

2

H REMARKS! The voltage supply for inputs and outputs for the users must be able to be switched in a deenergized manner via the key switch (terminal 15) - not via continuous positive.

3

4

5

2.5

Remove plug

H REMARKS! Removing the 25-pole equipment plug and engine plug when the control unit is on, i.e. when the voltage supply is on (terminal 15 on) is not permitted. 1. Voltage supply off

EMR 2 System Description

3

System Description

3.1

Utilization of the EMR 2

The purpose of the electronic engine governor (EMR 2) is the regulation of the speed of revolution of DEUTZ Diesel engines of the model series 1012/1013/2012/2013/1015 for applications in agricultural and construction machinery as well as in generating sets. It is designed for heavy duty also under difficult environmental conditions and possesses the corresponding protection classes. The governor fulfils all the functions of the mechanical governor (variable speed governing, torque limitations, LDA function) and makes further functions available.

3.2

System overview

Basically, the EMR 2 consists of the sensors, the control unit and the actuator. Engine-side as well as vehicle-side or plant-side installation are connected by means of separate cable harnesses to the EMR control unit. The cabling on the plant side is carried out by the vehicle or plant manufacturer. For arrangement on the engine and plant/vehicle side, see the following figure.

1

2

3

4

5

EMR 2 System Description

3.3

1

2

3

4

5

Description of functions

The sensors attached to the engine provide the electronics in the control unit with all the relevant physical parameters. In accordance with the information of the current condition of the engine and the preconditions (accelerator pedal etc.), the EMR 2 controls an actuator that operates the control rod of the injection pump and thus doses the fuel quantity in accordance with the performance requirements. The exact position of the regulating rod is reported back and, if necessary, is corrected, by means of the control rod travel sensor, situated together with the rotation magnets in a housing of the “actuator”. The EMR 2 is equipped with safety devices and measures in the hardware and software in order to ensure emergency running (Limp home) functions (see Chapter 7.1). In order to switch the engine off, the EMR 2 is switched in a de-energized fashion over the ignition switch. A strong spring in the actuator presses the control rod in the de-energized condition into the zero position. As a redundancy measure, an additional solenoid serves for switching off and this, independently of the actuator, also moves the control rod in the de-energized condition into the zero position. After the programming, that is carried out over the ISO 9141 interface, the EMR 2 is possesses a motorspecific data set and this is then fixedly assigned to the engine. Included in this are the various application cases as well as the customer’s wishes regarding a particular scope of function. The result of th is is that any later alteration must be reported back to the DEUTZ AG so that, in case of replacement anywhere in the world, the new control unit can be programmed with the current data set.

EMR 2 System Functions

4

System Functions

The EMR 2 makes a broad range of functions available and these can be activated by the applicationdependent configuration and the allocation of the inputs and outputs. It makes possible signal exchange between the engine (via the engine plug) and the EMR 2, as well as between the vehicle (via the vehicle plug) and the EMR 2. The signals can be transmitted as analog, digital, impulse modulated (PWM signals) and as CAN-Bus messages. Which functions are used, depends on the application conditions of the engine. Correspondingly, there are different variations of the functions and the pin assignments of the plugs. The functions of the EMR 2 refer to the speed control, quantity limitations (fuel injection), monitoring, vehicle and apparatus functions and communication and diagnostic interfaces. The EMR 2 offer a basic equipment on which all the optional variations can be structured.

1

2

3 Sensor inputs: ! ! ! ! ! ! ! !

Control rod travel Speed Coolant temperature (Charge air pressure) (Oil pressure) (2nd speed) (Coolant level) (Charge air temperature)

EMR 2 (Atm pressure sensor)

Set point input ! ! ! ! ! !

Micro

Key-operated switch (Pedal sensor) (Throttle lever) (Via CAN-Bus) (Voltage 0 - 5 V) (PWM signal)

4

5


4.1

Overview features Feature

1

Chapter

4.3

As variable speed, idling/end or fixed speed governor; choice of switchable governor features during operation, freezing the current speed, fixed speed governor for network synchronization or load distribution, overdrive speed

Set point input

4.4

By means of ! Pedal sensor and/or hand throttle ! External voltage signal (0 - 5 V) ! CAN Bus (remote electronics) ! Fixed speed signal (genset operation) ! Pulse width modulation (PWM) ! Touch control operation Up/Down (digital) Optimal adaptation to different applications

Torque limitation

4.5

Up to three performance curves can be set independently of each other within the framework of the engine limits

4.6

Constant, variable or switchable speed droop from 0 - 80 % for adaptation to the application

Speed control

2

3

4

Governor behaviour (speed

5

Description

droop) Engine Start/Stop

4.7

Engine switch-off by means of EMR actuator (additional


4.2

Function extensions

The EMR 2 has the same functions as the EMR but possesses extended and new functions. The new functions in detail are: !

Improved speed control

!

Third performance curve Smoke limitation = function of the charge air temperature

! ! !

Monitoring the charge air temperature, coolant level Altitude-referenced fuel quantity

1

2

!

Control of an engine brake

!

Special set point parameter for genset applications Special vehicle speed evaluation to DIN 11786

3

New functions via the diagnostic button: - fault blink codes - clearing the fault memory 1 2 Independent fault memories (mirroring the first fault memory)

4

Acquisition of a load collective Baud rate alteration for ISO communication possible

5

! !

! ! !

Possibility of a software update for the operating software via the


4.3

1

2

3

4

5

Speed control

Provision is made for various variations of speed control that must be programmed in advance (at the end of the programming) depending on the application case (power generation, building or agricultural machines) and usage conditions. The variations depend on the type of programmed and the selected functions. The following types of speed regulation (switches) are optional and are programmed at the works depending on the variant (pin assignment see Chapter 6.1): Function

Variable speed control

Variant

Description

Variable speed Pure variable speed governor without addi1) tion and switch-over functions governor Fixed speed governor Variable speed governor with fixed, pre-defined speed for gensets (1,500 or 1,800 rpm), desired speed of rotation is defined in the scope of customer supply (KLU). Change-over Variable speed governor with change-over switching speed 1 / switching possibility between two speeds. 2) 2 Change-over switVariable speed governor with change-over ching speed fixed/ switching possibility between a fixed pro2) grammed and a variable speed of revolution. variable Speed variable / Variable speed governor with change-over

Remarks

Only one variant can be selected


4.3.1

Swit witcha chable speed eed fu funct nction ions

The conditions for the switchable variants are selected by means of a switch (Input pin 18, GND pin 17 V plug). The switch closes a contact to -U Batt. The following is applicable for the switchable speed functions:

1 Switchable speed functions (for a selectable)

Switch closed (0/LOW)

Switch open1) (1/HIGH)

Speed 1/ speed 2

Speed 1

Speed 2

Fixed / variable speed

Variable

Fixed

Speed variable / freeze

Variable

Freeze

Variable speed governor / Min/Max governor

Varia riable ble spe speeed gov gover erno norr

Min/ Min/Ma Maxx reg regul ulaator tor

1) With an open switch, the underlined conditions above above are activated as preset values (default (default values).

2

3

4

The switching condition can be displayed with the aid of the SERDIA diagnostic software (see Chapter 7.3) 4.3. 4.3.2 2

Seco Second nd spee speed d inpu inputt (opt (optio iona nal) l)

This input can be used as a redundant speed input. If a second speed sensor has been installed, then the

5


4.4

Set point settings

The following variants for the set point settings of the governor can be configured:

1

2

3

Function

Variant

Set Set point point setti setting ng Acce Accele lera rato torr value sensor (SWG (SWG 1)

R e ma r ks

Setting with potentiometer (5 V reference reference 1) voltage, max. 30 mA , typ typ.. 1 kΩ linear, pin 25, input pin 24, GND pin 23, V-plug 2) )

Voltage

Setting by means of external voltage (0.5 4.5 V, input pin 24, GND pin 23, 23, V-plug)

Hand throttle (SWG (SWG 2)

Setting with hand throttle. The set point in the EMR 2 is determined determined by means means of a maximum function (5 V reference reference voltage, max. max. 30 mA 1), typ. typ. 1 kΩ linear, pin 25, input pin 20, GND pin pin 23 V-plug) V-plug)

Memory function

Freezing the current engine speed

4

5

Description

Replacement for pedal value sensor

Only possible in connection with the pedal value sensor (SWG (SWG 1)


4.5 4.5

Fuel Fuel quan quanti tity ty lim limitat itatio ion n (per (perfo form rman ance ce curv curve) e)

In order to set the engine performance and the desired torque course, the maximum injection quantity/ thrust must be limited in accordance with the settings. Provision is made in the the EMR 2 for three performance curves. The performance performance curve is created as as a characteristic curve with 13 freely selectable speed support points. The sampling points must be support points, whereby the sample of the engine is carried out with performance curve 1. The performance curve 2 is correspondingly corrected with the correction data of perfor mance curve 1. Function

Performance curve

Variant

Description

Performance curve 1

Quantity limitation with a performance curve (performance curve 1)

Performance curves 1/2

Switching between two performance curves

Performance curves 1/2/3

Change-over switching only via CAN

Performance curve change-over switching (Input) pin 19, GND pin17 V-plug

Remarks

1

2

Only 1 variant can be selected

3

4 Switch open (1/HIGH)1)


5


4.6

1

2

Droop control

One of the features of the electronic governing is that, in contrast to mechanical governors, the P-Gradient can be set to 0 % and switched over between two defined P-gradients. The maximum value lies at 80 %. For limiting the P-gradient relationship of the mechanical governor, provision is made for a speed-dependent P-gradient function by means of a characteristic curve with eight speed support points.

Function

Variant

Description

Remarks

P-gradient Constant P-gradient P-gradient is constant within the whole speed range.

3

Variable P-gradient

Speed-dependent P-gradient

P-gradients 1/2

Switching between two fixed P-gradients

Constant/variable

Switching between constant and variable P-gradients

Only one variant can be selected

4

5

Switchable variant pin 21, GND pin 17 V-plug

P-Gradient 1/ P-Gradient 2

Switch open (1/HIGH)

P-gradient 1

1)


P-gradient 2


4.8

Displays / Outputs (monitoring function)

By means of the digital PWM outputs and depending on the configuration, various signals can be displayed and output.

1

Fault lamp (Pin 4 vehicle plug)

A red fault lamp must be placed where it is easily visible at the customer apparatus side. The fault lamp serves as a rough estimate of the fault that has occurred; here the following means: ! Lamp 2 s on: Self diagnosis with switched on the voltage supply. Result: There are no faults. There is a fault message; however the system is operational (possibly limited). ! Continuous light: !

Flashing:

Serious malfunction - engine will be switched off or engine cannot be started.

!

Blink code:

Query malfunction locality by means of diagnostic button.

2

3

For detailed information see Chapter 7.1.

4

Output signals (maximum of 4 output signals possible) Function

Display functions

Variant

Speed 1 (pin 16, vehicle plug)

Description

Corresponding to the (No. of teeth on gear wheel) symmetrical square signal (Voltage level from 0 V to

5


Load collective

The EMR 2 measures the loading of the engine. For this purpose, the respective load and revolution regions are allocated to the engine operating hours. S1 to S9 are operating hours within the respective sector.

1

2

3

4

5


4.9

LDA function

For mobile applications, the injection quantity for acceleration and dynamic load increase is limited with reference to the charge air pressure (smoke quantity-characteristic field). Usage: protection of the exhaust turbo supercharger and prevention of smoke ejection.

1 4.10

Temperature-dependent start control

In order to prevent smoke ejection and for optimizing the governing relationship, the start quantity, the speed ramp and the governor parameters are controlled with reference to the temperature (required basic function).

2

3 4.11

Speed throttling (input F 7)

This function is designed for a driving speed evaluation is accordance with DIN 11786.

4.12

4

Engine protection functions

All monitoring functions can be provided with a message lamp on the plant side (dependent on the scope of the function and the pins that can be assigned).

5


Coolant monitoring

1

2

The user is warned by means of the message lamp when ! the coolant level falls below the warning limit and/or ! after a pre-warning period, the performance has been reduced by the EMR 2, or ! the the coolant level falls below the switch-off limit and, after a pre-warning period, the engine is switched off.

4.13

Altitude correction

The altitude correction is carried out by means of an Atmospheric pressure sensor in the control unit. Two different control unit variants are offered (with and without atmospheric pressure sensor).

3 4.14

4

Compensation for loss of performance due to fuel heating. Necessary variant with fuel temperature sensor.

4.15

5

Fuel volume control

Emergency running (limp home)

The EMR 2 provides comprehensive emergency running functions that are configured depending on the field of application. These functions are necessary in order that, in , the operation can be

EMR 2 Interfaces

5

Interfaces

The EMR 2 is equipped with various interfaces. The wiring is carried out on the customers side and must be integrated in the vehicle plug. For pin assignment see the application-dependent switch diagrams.

1 5.1

Diagnostic interface (basic function)

The end programming of the EMR 2 is carried out via the serial diagnostic interface (according to ISO 9141).

2

With the aid of a PC connected to an interface and the SERDIA (see also Chapter 7.3) diagnostic software measuring values, error messages and other parameters can be displayed and set - depending on access authorization. Furthermore, new control units can be programmed. Communication is only possible with the electric power switched on.

3

5.2

CAN-Bus interface

The CAN-Bus interface (Controller Area Network) is increasingly being used in vehicles and is suitable for measuring values and data exchange with one or more apparatus-side control units (hydraulics, drive control, etc.). The SAE J1939 protocol is utilized for communication.

4

5

EMR 2 Interfaces

1

2

3

4

5

EMR 2

6

Configuration and Parameter Setting


The EMR 2 is specially programmed and configured for each individual engine, which means that the EMR 2 contains a specially engine-specific data set. Configuration is carried out via the externally accessible diagnostic interface (ISO 9141) and is strongly dependent on the customer’s wishes, from the application cases and from the behaviour of a vehicle in operation.

1

Access to the various parameters is protected (by password) by means of access authorizations organized on four levels and can only be carried out by authorized personnel. More than 1200 different parameters are available. Access to these parameters, as well as to other data, can be carried out by means of the special SERDIA diagnostic software installed on a PC (see Chapter 7.3).  Important!

Rebuilding, as well as alteration to the parameters can only be carried out in conjunction with the corresponding DEUTZ operating partners. For this purpose SERDIA Level III is required. In connection with the above-mentioned possibilities, the changed data sets must be reported back to DEUTZ (see Service Note No. 0199-99-9287).

2

3

4

5


6.1

EMR 2

Function overview, pin assignment and configuration example

Summarized function overview with examples of function selection

The user-referenced selection is carried out using the DEUTZ pocket handbook

1

2

Functions

Plug engine/vehicle

Pin

Scope of function

Input/Output

(Example1) )

Scope of function Model No. No. of connection diagram engine side No.of connection diagram vehicle/plant side

0211 2291 0029 3766 0419 9752 0419 9780

Sensor inputs

3

4

Speed sensor 1 (camshaft) Speed sensor 2 (crankshaft) Charge air sensor (LDA function) Oil pressure sensor Atmospheric pressure sensor (in control unit) Coolant level sensor Charge air temperature sensor Fuel temperature sensor Coolant temperature sensor Control rod travel sensor

E E E E E E E E E

12, 13 10, 11 23, 24, 25 20, 21, 22 6, 8 4, 8 5, 8 9, 8 16, 17, 18, 19

E E E E E E E E E

E E E

14, 15 3 2

A A A

!

!

!

Actuator functions

5

Operating solenoid Dig. output (PWM) Solenoid Default functions (set point defaults via)

!

EMR 2

7

Diagnostic Button and Fault Indicator Lamp


Diagnostic button and fault indicator lamp must be placed in the vehicle or plant on the customer side. They can be used for diagnosis.

1

+UBatt Pin F 4

15

2

Fault indicator lamp

3

Diagnostic button -UBatt

GND

Diagnostic button switch diagram

4

5 © 06/02


EMR 2

Key switch (terminal 15)

On

1 Off Time Fault indicator lamp

2 On

3

2s Off

Case a) Lamp extinguished after 2 s: there is no active fault

4 On

5

2s Off

1s

1s

Time

EMR 2


Function control of the configured warning lamps

With the activation of the key switch (pin 15), the warning lamp is also switched on for the duration of the self-diagnostic (2 s). Key switch (terminal 15)

1

On

Off

Time

2

Fault indicator lamp

3

On 2s Off Time

On

e.g. warning lamp oil pressure

4

5


7.2

EMR 2

Diagnostic with Button and Error Code

With the diagnostic button there is the possibility of reading out the existing faults as blink codes and to delete the fault memory 1. The Diagnostic button and the fault indicator lamp are situated in the moving part of the vehicle.

1 7.2.1

2

3

Reading out a current fault memory blink codes

The fault indicator lamp shows a fault, e.g., it flashes or lights continuously. The Diagnostic button is depressed for a time period of 1 s to 3 s. The EMR 2 recognizes the request for a read out and starts to display the faults. (see blink code overview, Chapter 7.2.3). The read-out of the blink code is only possible after extinguishing of fault indicator lamp or after the initialization phase of the operating program. This means that the fault indicator lamp can also show continuous lighting after switching on if a fault has been recognized already after switching. The EMR 2 only shows active faults as blink codes. Diagnostic button

4

On 1-3s

5

Off Time

EMR 2


Steps for reading out the next fault: a The fault indicator lamp indicates a fault, e.g. it flashes of lights continuously. ! Press diagnostics buttons 1 to 3: the flashing or continuous light of the fault indicator lamp is extinguished b After 2 s: ! !

1

recognition by the EMR 2 (2×short flashes). The next blink code is output ( c, d ) After fault code output e 5 s pause, then display of flashing or continuous light.

2

The steps can be repeated until the last stored fault code is output. After that, the first fault code is shown again.

3

4

5


7.2.2

EMR 2

Deletion of the fault memory 1

The EMR 2 has two fault memories (1 and 2). Every fault is stored in both memories at the same time. With the aid of the diagnostic button it is possible to delete passive faults in fault memory 1. The fault memory 2 can only be deleted with SERDIA.

1 Diagnostic button

2

3

On

Off

<2s

c

a

Time Key switch (terminal 15)

4

5

On

Off

b

Time


EMR 2

p l e H

s k r a m e R

e s

t n e s e

d e n l a b r a o c s k n c e e s . h k d C c e . e r i e h u c C n . q e a n r t s o f i i i d t c e k e c c n a l e n h o p C c e r

d . n d a e r n i o i t u c q r e e f n i n o e c c a l e l b p e a R c . k o c h e h c a C T

f i ( l e n b n 1 a o y o r l i i i t c t o a a a r n v r s e e a e n p g p e t s r o e o o f n ( . y m y i c 2 c f f ) E r d n n o e e . e - l ) o i g g h e s r l r a c f n e e t b e ) i r a s m m l o 1 w i f e e r s a i e l ( n n v o y i a b . i c f ) r f r s a l n 2 o i o o n - d e a n r h n e e s g l r r i r v c e o e a h s a t e t v n i f v i t o e w r o w m o G s s o G ( E n

. n o i t a r e p o y c n e . ) g r 5 e 1 . m 4 e r n e i t r p a o h n r C e e v e o s G (

r . a s e e g s l m u o p r f m i e t . c l d n u e

t l u n o a i f l t a c e n n

k c e h C . ) 1 2 ( r e . t s e g m n i a t r t a e p s k d c e e h e p C s

) 3 . 3 . 4 . r p e t o t p s a h e C n i g e n e s E ( . e . t i m i l f o s s e

n o e s l u p m i ( r o t a u t c a o t e . l b e a d c o k m c t e h s C u r . h d t e e r l i b i u q s e s r o f p i e r o c f a l k p c e e r h d c n s a e r l c i o t h a e u t v c r o a F k . c h e h t e e C t . f s d o . o r o N k c k e h c e

. d . e r r i k u o c q s e n h e r e s C i r . f e f e l c o b a s t a l i c m r p e i r l o t s d l n n u e a a s f k r k c o c e s e n h e h C s C s , i t r l o n o i u s a n t f e c g s n u n e f i h c t g n n f i e u o r o l t f e i n r n i u l i 5 a o m 1 f . d h 4 . t t e r i d e a e i t W p . c t a a n o v i h o s t i C t s a c c e a e a e e e h S r t d y r t ) . n k e r a r o e s b n e e l s b g a n c

1

2

3

4

5


1

p l e H

2

3

s k r a m e R

4

5

e s

l i l e i o o r u k , s c l e e e s h v e n r i e p C l l . g l l e i i l i o o ( b n . k a n c e r i c t n e c a i s d w h i g r C n n e a r t e e . ) r u c k o a c p s s r e m s a h u n r h e e C p s p c l i o . n y e r n o h e v i o t w a t c i s e r r m a i e e l p v l l i o p b f a s a i d n e ( i m i e a t g g a a s y a s l i s e e e r d u . a m ) t s t r l i e u s t f r i a e m F p l A

d e e e n p i

. t l e n b a l a o c o d c n k a c r e o h s C n . e t n s a l e o r t o u c a r k e c p e m h e C t

e g r a d h c n k a c r e o h s C n . e s r i a e r e u t g r a a r h e c p . k m e c e l e t b r h i a C a c

y a l n s e e p d h o r a w d r s e n r i t f a a e g A p a . ) p e . a r l e s u v n i e o t l d i a y t ( r a e e r t i g p e v a m m i s e o l s t c l l e t e i r f m n a w t l l o e l u o m a o e i F c b t

y s a l n p e e o d r h d a w n r s e r i t f a a e g A p e . ) p r . a u t l e s a v n i r l e o d i e ( p y t a e m r i t g e e a t v m i s r o l s i c l l e a e i e r f m t g l r w o e l u a m a h e i F c b t

d e d e e c x e s a h

s a h . l e r e u v

EMR 2

. e l b k a c c e d h n C a . r l e o v s e n l t e s n l a e l o v e l o c t k n a c l e h o o C c

. e g a s s e m t l u a F s i ” l e v e l t n a l o o

d e e p . s e k d c o e m h C t . s r u r o t h a t u e t l c b i a s o t s e o p l b r a f c o k k c c e e h h C c . s e d d l e e c r i i e h u p s q e v e s r r s f o i F e c e . x c h E t a l 3 p e e . t e 3 r f . 4 d o . r . n o e a t n r N p o o i a t k h t a c e C c u e t h t e o c C e r a . S p k ) d c e e h e C p . s ) t s t p s d c u o o e t r r ( h . r r o k T e e “ c v . v e c n i o i t t i c h b d e e p s k c e h C . s r e t e . ) m a r 1 2 a ( p s k g n c i t e h t e C s

. e l b a c d l n e a u r f k o c s e n h e s C e . r l e u u t a f r k e c p e m h e C t l e u f n e h w o l w e s r b a s e p p o r p d a s n i i d ( a . ) l e g e g a e v a r e s u s t l e a y r r e m t e p v l o u m a e c e F t r d e d e e c x e s

EMR 2

p l e H

l i . l e i o t i o r u k , s c m l i s e l e e v r h f f e p C o l . l i l e i l h o c ( o b t i k a e c c w n e i h s d g n C a e n e . ) r r u k c p o s s s e m n h u e e r C p s p

s k r a m e R

e s

. e l b k a c c e d h n t . i C a . r l o m i e s l v n f f e l e o t s n l h a e c l t i o v e l o w c t s k n k a c c l e e h o h o C c C

e g . r i t a d m h c n i l k a f f c r e o o h s h C n c t . e s i r i e w a r s e u t k g c r a a r e h h e c p C . k m e c e l e t b r h i a C a c

p o t s y c n e g r e m E t i m i l f f o h c t i w

d e d e e c x e s a h

s . a t i h e m r i l u

. e l b k a c c e d h n C a . r l e o v s e n l t e s n l a e l o v e l o c t k n a c l e h o o C c

. k c o l t r a t S . p o t s y c n e g r e m E s i ” l e v e l t n a l o o

. ” k n c o i e t f h i a e c m , r c e i l a f l b p a n o e r c C , k “ r c r o e o t h a f u s t C t . i c d m a e i r l k i c t l e u q h e u a C r f

k c e f h i s e c , s c e e l a l b n e p a f i e r c R , k “ . r c r ” o e o n t h a f o u i s t C t t . i c a d m a e i m r l k r i t f i c l n e u q u h e a o C r f c

r o t a u t c A . f f . o - d h e c t t a i r e w s p y o c e n b e t g r o e n n m a E c n i t l u a F . d . e t n


. / l e s b d a o f c r i r e r o c o t t a a a l u u p t t c c e a r a , k / r p c o e t m h a u u C t p . c n d a o e i r k t i c c e e u q j h n C i e r n e h w s r a e p . ) p a % s i 0 d ( 1 e < g s a i s s e e c n m e t r l e f u f i a F d r . o n h t d e a e e s p w t i m l l e o m b e r a e v j a t n r r c t o l o c t n e o l a r r

. e n y n . v o r m e e r i f l a c a a i d a s b . n r d a s , n , c g a e e r g e c k a t o y d n l r e f c n o b f P c k f l a a u l a i c a e o . b f a e t c r k p a a / d n e b d c z . c y f e r o i i l I d i n l n a e i t v p a f . d e i a b r a e p n n r u n e f d i s u a o q g t e g a S a i i f s e r k e g c e m f s s Z o a c t e g i e t h t h i i c l i T t k t a a t h i a U m l c m u t t i i l t C w l E e l . u f t S m c t h a D d o o o l l a v f . C t u e u s . m r k u k k s i a e e n f c c c r a f i o t a u e u e u e e a l l f u t h q h h e a a g e h n o C r C C v t v a i S r o n r C e v D d o E e r . i G e . u k s q c u e o o r l t n . t n r i o ) i a 4 t n t . s e a r 8 / k b r i a p t l a e t o t e c p s b r a h t o e o t C n n a i u e g n t n a c e s E c a ( n o i t a z e i l h t a f u o . q t s e u e u r p l o n a

1

2

3

4

5


1

p l e H

EMR 2

r e t p a h C t . i , e n n e s u o ( i t r l o c t r t e o s n n i n s o c o e c r k g N n c e i h A C t C a , n k i ) c 4 e m . r h e 2 C t 1

. t ) t u i p u t c u r i o l c a t r t i o g h i d s f r o o k e l b a r a e c b k e l c b e h a c C (

2

3

s k r a m e R

4

5

e s

. f f o d e h c t i w s s i l e v e l r e v i r D t a ) k a e r b e l b a c

. t n e d n e p e d n o i t a c i l p p A

. e g a s s e m t l u a F s e r i s e t t i o u n b - p s y e l N d A s u

n o d e a c a r l o p r e e f f b

d e l n b a a r c o , s n n o e i t s . c k d e e n c e r i n h o C u c . q e N n r o f A i i C t c e k e c c n a l e n h o p C c e r

. n i a g a m r n o f o n i d n y t a l f f u a o f f e n I c o . i i t n i i v n a r e g g S i a Z h k c T c t i U e E w h S C D t o n n a c e n i g n e . f f o h c t i w s y . c d n e e t r g a r t e s m e E b n . i g y r n o i m m e m m a r e g u l o r a

m d a e l r l g a o r c p o s f ( o r g

5 9 f 8 . f f 3 I e ( o . i c n s n i v r i o e t a r e t i e n g S a g m Z k i a T r h c e U a c h t E p i C f w D . o n m S i s . a ) g r e o 6 a u f l 9 i n a 8 n v y 3 o t e l t d d o n n u a N a a f

g n i k r o w f o r . g


EMR 2

p l e H

s k r a m e R

e s

. n i a g a m r n o f o n i d n y t a l f f u a o f . f e n I c o . i i t i n v i n a r e g S i g a Z h k c T c t i U e E w h S C D . ) n e e g h n a w r s r l a a e m p r p o a n s e i h d ( t n e i g n a i s a s g e a m r t e l u w a o F p e h t n i t o n r o t a u t

k c e h Z h c T t i C U . w E n i D S . a y g l a m p r o p n f u o n i s d y e n l g a t u a f t a l f f o o f . v n I . e c k o n i c t i i v i e r a n h g g e C i a S . ) n e e g h n a w r s r l a a e m p r p o a n s e i V h d ( t 5 n e i e u g l n a a i s v s a e g a y r a m r l i t e i l x u w a o u F p A t o n r o t a u t . c e a g r n o

. n i a g a m r n o f o n i d n y t a l f f u a o f . f e n I c o . i i t i n v i n a r e g S i g a Z h k c T c t i U e E w h S C D . ) n e e g h n a w r s r l a a e m p r p o a n s e i h d ( t n e i g n a i s a s g e a m r t e l u w a o F p t i n u l o r t n o c . r e o g f n a

g n i e . n r h ) o t e w i g n s r n o a a r m e l e . p p a r d u a m t s e s r i a o s d v ( n e r i t n p e c i a g n c i a i r e s a e d s g h n e a p o m r s i t e t o l w c u o m a t n u F p A f

n i t o n e r

n f I . i o s . t n i . g i e n n a i c g t i g i t a v e r h s e c t k t i c S c w e e Z h r T r S . C o s . U c r i E n r t e a D o g e f a m a m t a n r o a r o f d a n i d k p n y c e a t l e v f h a f u a C S o f

. d e t r a t s e b t o n n a c e n i g n E g a t i a n d s v f r a s o u / c c r m t u o e s y e l k c n m e o a

n o d d n a y t n f l f u a a . f 7 o n f e 9 I c o . i 8 i t n v 3 ( i i n a r e s g g S r i e Z t h a T e t k c i c U m e E a w h r S C a . D . m p ) n 8 e i r t 9 o a f o 8 g n N 3 a i t o n n a c e n i g n E . f f o h c t i w s y . c d n e e t r g a r t e s m e E b d e l l a c o s ( t . l ) u t l a

1

2

3

4

5


7.3

1

3

4

With the aid of the SERDIA diagnostic software, the fault messages stored in the control unit can be read out and evaluated.

Information is displayed on the following: - Fault locality (e.g. pedal sensor, coolant temperature sensor). - Fault type (e.g. lower limit exceeded, sporadic error). - Environmental data/operating data (speed and operating hours at the time of the occurrence of the last fault). - Number of fault localities - Frequency of the fault - Fault status ( active - fault persists / passive - fault eliminated). Fault messages of non-current and eliminated faults can be deleted w ith SERDIA. !

5

Diagnostic possibilities with the SERDIA software

SERDIA (Service Diagnosis) is a software program with the aid of which the user can monitor the measurement value on a running diesel engine from a PC or Notebook computer and can thus recognize faulty operating behaviour. ! With a stopped engine, it is possible to enter certain parameters in a targeted manner from the PC into the control unit (parameter setting) in order to change the operating behaviour of the engine. !

2

EMR 2

Function test

In the function test, the outputs and the control rod travel can be activated with the engine stopped. !

Input/output assignment

EMR 2

8

Replacement of system components


In case of malfunction, the individual system components such as sensors, control unit, actuators, can be replaced but not repaired.

8.1

Replacement EMR ↔ EMR 2

The EMR 2 is a further development of the EMR. But are not compatible in the case of replacement. Only the part numbers (TN) that count for the respective system can be utilized.

8.2

1

2

Features of the Replacement of the Control Unit

Each control unit is fixedly assigned to the engine (engine number) in accordance with its individual application case. In case of a replacement, therefore, the control unit must be equipped a) with its engine-specific data set and b) with a ticket [engine number...]

3

4

Programming with an engine-specific data set is only possible with SERDIA (Levels III and IIIa) and can be carried out in two ways: !

By ordering a new control unit with information of the engine and part number (completion by DEUTZParts Logistics).

5


EMR 2

8.3

Features of the Replacement of the Actuator

8.3.1

Model series1012/1013/2012/2013

The actuators are replaceable on a 1:1 basis without additional programming.

1

2

8.3.2

Actuator (EDC-actuator) and Bosch pump belong together (one TN). In the case of a replacement, the actuator (with the pump) must be calibrated with the control unit. This calibration is necessary (with SERDIA Level IIIa), because the new characteristic curves must be stored in the control unit.

8.4

3

Model series 1015

Combination EMR, EMR 2, Control Unit and Actuator

EMR control units, see also SM 0199-99-9334. Control unit

Actuator EMR 1012/1013/2012

Actuator EMR 2 1012/1013/2012

EMR



Fault message Engine cannot be started

EMR 2





4

5

EDC actuator 1015

Calibration required

The EMR 2 control unit automatically recognizes the actuator EMR or EMR 2. In order to limit errors, therefore, an “old” EMR actuator can be combined with the EMR 2 control unit. In reverse, a “new” EMR 2

EMR 2 Technical Data

9

Technical Data

9.1

General Data

1 Designation

Nominal voltage Maximum cable length governorengine Current consumption (inc. actuator) Permissible operating temperatures Dimensions Weight Air humidity Type of protection Shock permissibility Vibration

Technical data / Remarks

12 and 24 V DC, working range 10 ... 36 V DC, engine starting is possible from 6 V

5 m (remote engine extension) A, ≤ 11.5 A for 60 s, (fuse 15 A) -40 ... +85 °C 231 × 204 × 62 mm (length × width × height) 1.6 kg < 98 % (at 55 °C) IP 66k, IP X7, IP X9k to DIN 40050 < 50 g < 1,5 mm (at 10 ... 20 Hz) < 180 mm/s (at 21 ... 63 Hz) < 7 g (at 64 ... 2.000 Hz)

2

≤ 9

3

4

5


9.2

Signal Specification Pin1)

Pin type/Signal type

Technical data / Remarks Inputs

1

2

3

4

F4, F6, F7, F18, F19, F20, F21, F24, Digital input M6, M11, M21, M24

Ulow < 2 V, Uhigh > 6,5 V, Rpull = 4.7 kΩ after +UBatt

F4

Digital input

Isink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching), Diagnostic button (closing) after -U Batt

F20, F24, M21, M24

Analog input

Uin = 0 ... 5 V, fg = 7 Hz, Ri = 220 kΩ, Uref = 5 V ± 25 mV, Imax = 25 mA

F18, F21

PWM input

Ulow < 2 V, Uhigh > 6,5 V, Rpull = 4,7 kΩ, fin < 500 Hz (typ. 100 Hz), Tan /Tper = 5 ... 95 %

M11, M13 F7, M11 M17, M18, M19

Frequency input

Inductive sensor, Uin = 0,2 ... 30 V AC, fin = 25 ... 9.000 Hz

Speed input

max. 255 Impulse/m

Inductive input

M4, M5, M9

Temperature input

Control travel sensor NTC resistance measurement, max. ± 4 °C (tolerance, typ. ± 2 °C) Outputs

5 F4

Digital output

Isink < 0.5 A, Urest < 0.5 V, Ileck < 0.1 mA (ground switching),


9.3

Plug assignments

The 25-pole plugs of the EMR 2 control unit are mechanically coded (different part numbers). Because of the different pins, the vehicle plugs (F) or the plant plugs (F) and engine plug (M) only into the sockets provided for them, so that incorrect plugging in is impossible. 9.3.1

1

Engine Plug (M)

Pin No.

Designation

Description

2

1

Reserve

Reserve

2

Output: digital 3

3

Output: digital 4

Digital output for solenoid1) For heating flange (optional)/ glow plug (optional)

3

4

Input (optional) Temp 1

5 6 7

Input (optional) Temp 2 Input (optional) DigIn 5 Output: PWM2/digital 6

Fuel temperature2) Charge air temperature Coolant level / oil level

4

8

GND

9

Input: analog 7

Reference potential for analog signal at pin 9 Analog input for Coolant temperature sensor (NTC)

5


9.3.2

Vehicle Plug (F) / Plant Plug

Pin-No.

1

2

3

4

5

Designation

1 2

U Batt GND

3

Output: digital 2

4

Input / output: DigInOut

5

Output: PWM 1/Dig 1

6

Multi-function input: DigIn 3

7 8 9 10 11 12 13 14

Input: digital 10/velocity NC NC L-line K-line CAN high CAN low U Batt +

Description

Negative pole at battery (clamp 31) Reference potential for signal PWM or digital output, various functions Fault lamp and diagnostic button PWM or digital output, various functions Genset applications/gear shift/motor brake Speed signal (tacho input) Not occupied Not occupied Serial ISO 9141 interface Serial ISO 9141 interface Interface for CAN-Bus Interface for CAN-Bus Positive pole for battery (clamp 15)


9.4

Sensor Data

Temperature sensor (NTC), coolant

Pins:

Signal pin 9, GND pin 8, engine plug

1

Measuring range: -40 °C to 130 °C Temperature sensor (NTC), fuel

Pins:

Signal pin 5, GND pin 8, engine plug

2

Measuring range: -40 °C to 130 °C

3 Temperature sensor (NTC), charge air

Pins: Signal pin 4, GND pin 8, engine plug Measuring range: -40 °C to 130 °C

4

Oil pressure sensor

Pins:

Signal pin 21, GND pin 20, reference voltage +5 V pin 22, engine plug

Measuring range: 0 to 10 bar

5


Coolant level sensor

Pins: Signal pin 6, GND pin 8, engine plug Measuring range:

1

Atmospheric pressure sensor

Depending on unit configuration, integrated into control unit, see Chapter 4.13

2

3

4

5

EMR 2 Index of Specialist Terms

10

Index of Specialist Terms

AGR

Exhaust gas return

Actuator AMP plug

Actuator Multi-pole plug of the AMP company

Baud rate

Data transmission speed [Bit/s]

CAN-Bus EDC-actuator

Interface (Controler Area Network) Actuator of the Bosch company

EEPROM EER 2

Memory module in the microprocessor Electronic engine governer

ELTAB

Electronic engine pocket handbook

EMV F-plug

Electromagnetic compatibility Vehicle plug / plant-side plug at the control unit

GND High

Mass (Ground) Switch open (high)

ISO

International Standard Organization

Clamp 31 KLU

Minus clamp at battery Scope of customer supply

1

2

3

4

5

EMR 2 Index of Specialist Terms

1

2

3

4

5

EMR 2 Index

11

Index

A Actuator .......................................................................................... ........................................................... 100 Actuator functions ............................................................................................. .......................................... 86 Altitude correction ............................................................................................. .......................................... 82 Atmospheric pressure sensor ......................................................................................... ..................... 82 106

1

,

2

B basic equipment ................................................................................................ .............................. 70 71 72 Blink codes ..................................................................................... ............................................................. 90 ,

,

3

C CAN-Bus ......................................................................................... ............................................................. 86 CAN-Bus interface ............................................................................................. .......................................... 83 Charge air monitoring ........................................................................................ .......................................... 81 Charge air pressure sensor ................................................................................ ........................................ 105 Cold start installation ......................................................................................... .......................................... 82 Configuration .................................................................................. ............................................................. 85 Configuration example 86

4

5

EMR 2 Index

F

1

2

3

Fault blink code overview ................................................................................................. ........................... 93 Fault group ........................................................................................ ........................................................... 93 Fault indicator lamp ............................................................................................. ........................................ 87 Fault lamp ......................................................................................... ........................................................... 79 Fault locality/fault description .............................................................................. ........................................ 93 Fault memory ....................................................................................................... ........................................ 92 Fault no. ............................................................................... ........................................................................ 93 Fuel quantity limitation (performance curve) ......................................................................................... ....... 77 Fuel volume control ............................................................................................. ........................................ 82 Function control ................................................................................ ........................................................... 89 Function extensions ............................................................................................. ........................................ 73 Function overview ................................................................................................ ........................................ 86 Functions .......................................................................................... ........................................................... 86

I 4

Important notes ................................................................................ ........................................................... 67 Installation guidelines .......................................................................................... ........................................ 67 Interfaces .......................................................................................... ................................................... 83 102 Introduction ....................................................................................... ........................................................... 65 ,

5

L

EMR 2 Index

R Replacement of system components ................................................................................................. ......... 99

S Scope of function .............................................................................................. .......................................... 86 Second speed input ........................................................................ ............................................................. 75 Self-diagnostic ................................................................................ ............................................................. 87 Sensor data ..................................................................................... ........................................................... 105 Sensor inputs .................................................................................. ............................................................. 86 SERDIA .............................................................................. .......................................................................... 98 Set point settings ............................................................................................... .......................................... 76 Signal specification ......................................................................... ........................................................... 102 Signal type ...................................................................................... ........................................................... 102 Software .......................................................................................... ............................................................. 98 Speed control ................................................................................. ............................................................. 74 Speed sensor .................................................................................. ........................................................... 105 Speed throttling .............................................................................. ............................................................. 81 Switchable speed functions ............................................................................... .......................................... 75 System description ......................................................................... ............................................................. 69 System functions ............................................................................................... .......................................... 71 System overview ................................................................................................ .......................................... 69

1

2

3

4

5

EMR 2 Index

1

2

3

4

5

EMR 2 Connection diagrams

12

Connection diagrams

The following connection diagrams present the maximum scope of the EMR2. Customer or model-specific wishes are not taken into account. 12.1 Connection diagram vehicle / plant side 12.2 Connection diagram vehicle side (sheet 1) 12.3 Connection diagram vehicle side (sheet 2) 12.4 Connection diagram for CAN-Bus and diagnostic line Only the switching diagram specific for the particular engine is binding. This is prepared by the DEUTZ customer representative before supply of the first engine as the switching diagram is not part of the documentation supplied with the engine. Methods of obtaining the switching diagrams are: ! Sales or customer representative, or !

Dept. Sales Documentation (Format DIN-A2) or

! !

Sales drawing CD-ROM or Engine pocket handbook (from page 3.150, size DIN-A4) or

!

ELTAB CD-ROM

1

2

3

4

5

EMR 2

12.1

Anschlussplan Fahrzeug-/Anlagenseite

Anhang/ Appendix

Connection diagram - Vehicle side / Unit side

Anhang Appendix

12.2

Anschlussplan Motorseite (Blatt 1)

EMR 2

Connection diagram - Engine side (sheet 1)

EMR 2

12.3

Anschlussplan Motorseite (Blatt 2)

Anhang/ Appendix

Connection diagram - Engine side (sheet 2)

motorseite2 © 06/02

Deutz EMR2 Electronic Engine Governor

Recommend Documents